Carton



Nov. 24, 1964 H. s. LEVKOFF 3,158,310

CARTON Filed Aug. 8, 1962 2 Sheets-Sheet 1 INVENTOR HENRY s. LEVKOFF ATTORNEY Nov. 24, 1964 Filed Aug. 8, 1962 FIG. 5

H. S. LEVKOFF CARTON 2 Sheets-Sheet 2 HENRY S LEVKOFF ATTORNEYS United States Patent 3,158,310 CARTGN Henry S. Levlrofi, Great Neck, NX. Standard Folding Trays Corp, 85th St. and 24th Ave., Jackson Heights 69, NY.)

Filed Aug. 8, 1962, Ser. No. 215,571 1 Claim. (Cl. 22931) This invention relates to improvements in cardboard boxes or cartons of the tray type. The blanks for such cartons are composed essentially of a bottom panel having a longitudinally extending end panel at each end and also having side panels adjoining the opposite sides of the bottom panel, each side panel having longitudinally extending end panel portions connected at each end of the blank to the side and end panels by a folded web or gusset fold portion.

In setting up such a carton the side panels with their connected end panel portions including the gusset fold portions are first folded fiat against the bottom panel and its end panels. Then each of these end panels and their overlying gusset fold portions and end panel portions are folded upwardly about the hinge scores which respectively connect the end panels with the bottom panel and the gusset fold portions with the side panels. Simultaneously with such upward folding or bending of the end parts of the carton blank, the side panels are partially released allowing them to partially unfold'by the resiliency of their hinge scores.

This combined movement causes the gusset fold portions to fold upwardly to form the corners of the carton. Thereupon the end panel portions which are hinge scored to the respective gusset fold portions are folded inwardly over the top edges of the corner portions just formed and their free ends are folded downwardly and locked in slots which are provided at the ends of the bottom panel. This completes the formation of the carton end walls, leaving the end panels projecting vertically upward, and completes the setting up of the carton.

Difiiculty has been experienced with the apparatus heretofore used for setting up such cartons because of the occasional incomplete folding or forming of the end walls of the carton. Usually the difficulty stems from the improper folding of the gusset fold portions at the commencement of the upward bending of the carton end portions and the upward unfolding of the side panels. When the gusset fold portions do not fold as intended the result is that the locking flaps or tabs are not locked in the slots provided for this purpose.

The primary object of the present invention is to provide a new carton blank specifically designed to be used with automatic carton setting-up apparatus which will eliminate, or substantially eliminate the production of cartons with incompletely folded end portions and the resulting number of cartons which must be rejected and scrapped.

In accordance with my present invention I have discovered that by first bending the end panels and their overlying gusset fold portions in a reverse or downward direction about the hinge scores which respectively connect them with the bottom panel and the side panels, and thereafter bending these parts upwardly while substantially simultaneously releasing the side panels the gusset fold portions will be folded in the intended manner so that on completion of the folding of the end parts of the carton, the locking flaps or tabs Will be locked in their slots in substantially every instance.

Furthermore, two locking tabs which I provide one on the end panel portion and one on the gusset fold portion at each end of the carton, enabling my improved apparatus to attain a control of the unfolding of the p a C6 Patented Nov. 24, 1964 side panels which greatly facilitates the proper release of these panel portions with respect to the timing of the upfolding of the carton end portions, and thus assists in achieving the proper unfolding of the gusset fold portions.

The invention will be further disclosed and discussed in connection with the accompanying drawings. In these drawings:

FIG. 1 is a perspective view of the apparatus;

FIG. 2 is a somewhat enlarged perspective view of a portion of the apparatus shown in FIG. 1 with a carton blank in position ready to be set up;

FIGS. 3 and 4 are perspective views of the folding mechanism for the right end of the carton shown in FIG. 2 and with parts in diiferent positions;

FIG. 5 is a detail sectional view taken on line 5-5 of FIG. 1;

FIG. 6 is a similar view taken on line 6-6 of FIG. 3;

FIG. 7 is a plan view of the carton blank of the type set up by the apparatus;

FIG. 8 is a perspective view showing the right end portion of the carton with the parts thereof forming the end'wall partially folded or set up; and

FIG. 9 is a View similar to FIG. 8 of the left end of the carton with the folding of the end parts completed.

Referring firstv to FIG. 7 the type of carton blank which is operated on or setup by the present apparatus has a bottom panel 19 having at its opposite ends end panels 11 and 11'. These are secured thereto by hinge scores 12 and 12' having central locking slots 13, 13'. Side panels 14 extend along the sides of bottom panel 10 and are secured thereto by hinge scores 15.

At the ends of the blank there are end panel portions 16, 16' and 17, 17'. End panel portions 16, 16' are connected to the blank by folded webs or gusset fold portions 18, 18'. Similarly end panel portions 17, 1'7" are-connected to the blank by gusset fold portions 19 and 19'. Each of these gusset fold portions is joined to its adjacent side panel by a hinge score 20, 20'. Each of the end panel portions is joined to its adjacent gusset fold portion by a hinge score 21, 21. Each gusset fold portion has a cut 22 extending about half the width of the adjacent side panel, substantially parallel to hinge score 21 or 21' and bisecting the gusset fold.

At the inner end of cut 22 there is a 45 hinge score 23 extending to the adjacent corner of the bottom panel. This 45 hinge score enables the gusset fold portions to form four corners of the box when the end parts are folded as shown in FIG. 8. It will be observed that the edges 24 of the gusset fold portions which extend beyond the hinge scores 20, 2t) become the top edges of the end corners of the box. The outer extremities of end portions 11 and 11' which are beyond cut scores 25, 25' constitute extensions 26, 26' which are bent inwardly, as indicated in FIG. 9. 7

Referring now to FIG. 1 typical carton setting up apparatus with which my new carton blank is designed to be used includes a conventional blank folding mechanism shown in the upper portion of this figure, and conventional locking head mechanism for folding and locking the end parts of the carton, which is shown in the lower portion of FIG. 1, and also in FIG. 2.

In the operation of the blank folding mechanism the fiat unfolded blanks 27 are fed intermittently over a flat horizontal table 23 by means of a series of three feed rollers 29, 30 and 31. These rollers are fixed on parallel horizontal shafts which are journalled in the machine frame and which are continuously rotated in the direction indicated by the arrows by means of driving chains 32 and 33 which are trained about sprockets shown as being secured to the end portions of these shafts.

To assist in carrying the blanks 27 along table 28 an endless belt 34 may bearranged to move over the surface of the table, being carried at its ends around suitable pulleys one of which is shown at 35. This belt is driven by means, not shown, to travel at a speed corresponding to the feeding speed of rollers 29, 3t) and 31.

As the blanks 27 move toward the right in FIG. 1 the bottom panels thereof pass beneath stationary rails 36 which hold the bottom panel of each carton while the side panels 14 are folded upwardly by stationary folders or plows 37. The folded blanks 38 are discharged onto a flat plate or table 39 with their side portions folded flat against the upper surface of bottom panel fit. As the folded blanks 35; are successively received on table 39 the side panels 14 with their connected end portions 16, 16' and 17, 17' are held in flat folded condition by means of pairs of holders 40 and 41.

Upon being delivered onto table 39 each blank is fed toward the left horizontally by a reciprocating feed plunger 42 which engages the rear or trailing side edge of the folded blank and moves it sidewise to the left as viewed in FIG. 1 until it is opposite or in line with the two folding and locking heads which are indicated generally by reference numerals 43, 43. In FIG. 1, the folded blank 38 is shown at about the mid-position of this lateral move ment by plunger 42, the purpose being to show the downward bending of the end parts of the blank (gusset folds, end panel portions and panels) alongthe hinge scores 23 and This is accomplished by two stationary cams or horns 44, 44'.

These horns are each fixed at their right ends to the machine frame, such support being visible in PEG. 1 with respect to horn 44 and shown in detail in FIG. 5. Horns 44, 44' are stiff metal rods which are bent or curved as shown so that as the end parts of the folded blank 38 pass beneath them, such parts are bent downwardly to a slight extent, for example, to from about to about 45 from the horizontal. To permit such down-bending, table 39 is cut away at its opposite side edges as shown in FIG. 1, so that the spacing of these edges corresponds with the distance between hinge scores 20 and 2a This downward flexing or bending of the end parts, particularly those parts forming the gusset fold portions 18, 1'3 and 19, 19 has been found to condition the end parts so that when they are later on manipulated by the folding and locking head mechanisms 43, 43' they will fold properly as indicated in FIG. 8.

The carton blanks (FIG. 7) are provided at each end with two laterally projecting control or holding tabs 4-5, 45 and 4d, 46'. These project from the side edges respectively of gusset folds 18, 18 and of end panel portions 16, 16'. They are separated by notches 47, 47'. During the previously described folding of the carton side panels 14, into substantially fiat position on top of the bottom panel 10, as shown in FIGS. 1 and 2, the inner control tabs 45 and 45' are made to project above the correspcndingedges of gusset fold'portions 19 and 19' and the outer control tabs 46, 46' beneath end fold portions 17, 17'.

The pair of control tabs 45, 46 at one end and the pair of control tabs 45146 at the opposite end serve to interlock the two side panels 14- and their corresponding end parts so that by holding either one of the side panels 14 flat, or at a somewhat raised angular position, the opposite side panel will be held in a complementary position.

Referring to FIG. 2, as plunger 42 nears the end of its stroke toward the left, the right-hand or trailing side panel 14 is held in flat position by the end portions of folders 41 while the end parts of the opposite or left-hand, or leading, panel 14 pass beneath two hold-down fingers 48, 48'. During this final movement of blank 38 the holding of the side panels is transferred from the holders 41 to the hold-down fingers 48, 4-8, but the above described interaction of the control tabs causes the side panels and their connected end parts to be maintained in flat position in contact with the bottom panel iii.

In FIGS. 3 and 4 is shown the setting-up mechanism position is also illustrated in FIG. 8.

. 4 for operating on one end of the carton blank, namely, the right end, This mechanism is conventional, as previously indicated, and comprises a pivoted folder 4-9 and a locking head 50. Folder 49 is pivoted at its lower end just below the table 39, and locking head Stl is pivoted at 51 to the upper end of folder 49. Both parts are operated by an actuator 52 which is connected by a link 53 to the locking head 59. Link 53 is pivoted at 54 to actuator 52 and at 55 to locking head 5%. Actuator 52 imparts its upward folding movement to folder 49 by means of a compression coil spring 56.

It will be understood that the locking head 43 is similarly constructed and operates simultaneously with locking head 43, operating mechanism (not shown) being provided which is of a conventional nature and which operates in timed relation to the, movement of feed plunger 42. Hold-down fingers d8, 43' acting on the leading side of the carton blank 33 maintain it in flat folded (FIG. 2) position and as described above during the first part of the folding movement of the end parts of the blank by the folders 49 and 49. During this folding movement these end parts are folded upwardly about the hinge score 12, f2 and 2d, 20.

It is important, however, to release hold-down fingers 48 and 48 in properly timed relation to the upward swinging movement of folders 49, 49', in order that the natural resilience of the material of the blank may cause the simultaneously upward movement of side panels 14 and the gusset fold portions, thereby causing the folding or bending of the gusset fold portions about the 45 hinge scores 23 in the process of forming the end corners of the carton. This release of hold-down fingers 48, 48' is accomplished by means of a pivoted mounting 57 for the respective hold-down fingers which is turned on its pivot pin 58 (FIG. 6) by the motion of the respective folders 49 and 49' during their upward swinging movement.

Thus, pivot pin 58 is fixed in the frame of the machine closely adjacent one side of folder 4-9 and mounting 57 has an extension or lug 59 which projects into the path of the sideedge of folder :9. A coil spring 60 on pivot pin 58 is arranged to swing the mounting to hold finger 48 in the position shown in FIGS. 1, 2 and 6, where finger 48 operates to hold the blank in fiat folded position. As folder 49 swings downwardly it engages lug 59 and turns mounting 57 on its pivot to swing finger 48 through an angle of to the position shown in FIG. 4 where it has swung free of the carton blank.

FIG. 3 illustrates the position of the parts of both the folding mechanism andthe carton blank substantially at the instant of release of the carton blank by hold-down finger 48. The side panels 14 have sprung upwardly and gusset fold portions 18 and 19 have commenced to fold about their 45 hinge scores 23. This The upward movement of folders 49, 49' continues wherein the end parts of the carton are bent to vertical position.

The further movement of actuator 52 urges link 53 to the left and causes the locking head 50 to be swung .to the left and downwardly to vertical position of FIG. 4 where the end portions 16 and 17 are folded about hinge scores 21, and the tips of the end portions forced into the slit 13. This is shown in FIG. 9 for the corresponding parts at the opposite end of the carton. During the locking movement the extensions 26, 26 of the end portions are folded about cut scores 25 and 25', and upon the return of the locking head and folder to the open position shown in FIG. 2, this extension is left in the angular position of FIG. 9.

By the reverse flexing of the end parts of the folded carton blank, that is, the end panels and gusset fold portions about their respective hinge scores prior to the setting up of the carton, that is, the folding of the end panels, gusset fold portions and end panel portions, and the unfolding of the side panels, the carton setting-up operations can be performed just as rapidly as heretofore but with the substantial elimination, of rejects, or incorrectly set-up cartons. The provision of the double control tabs, or pairs of tabs, on the respective gusset fold portions and end panel portions at each end of the carton blank facilitate the control of the opening of the side panels simultaneously with the bending of the end parts into upward and then into, final locking position. Also the pivoted control fingers for controlling the side panels and its connected end parts on the outer side of the carton, and the stationary holders for controlling the corresponding parts on the inner side of the carton at the setting-up position, together with the actuation of the pivoted fingers in timed relation to the operation of the folding and locking mechanism for the end parts additionally facilitate the settingup of the carton.

It will be understood that changes can be made in the mechanism described herein and that, consequently, the scope of the invention is set forth in the appended claim. 7

This application is a continuation-in-part of my United States application Serial No. 3,080, filed January 18, 1960, now US. Patent 3,071,048, dated January 1, 1963.

I claim:

In a blank for a tray-type carton comprising a bottom panel, a side panel on each side thereof, end panels projecting from the opposite ends of the bottom panel and connected thereto by a hinge score, and end panel portions each connected to the respective end panels and to said side panels by a gusset fold portion, said gusset fold portions and said end panels being joined by hinge scores to said side panels and said bottom panel respectively, the improvement which comprises providing each gusset fold portion and each end panel portion on one of the side panels with a laterally projecting lock tab for intermeshing the adjacent gusset fold portions and end panel portions with the opposite side gusset fold portions and end panel portions when the side panels and their connected gusset fold portions and end :panel portions are folded against the bottom panel, and said end panel portion lock tab being separated from said gusset fold portion lock tab by a small distance and extending outwardly a greater distance from said end panel portion than the gusset fold panel portion lock tab extends from said gusset fold portion.

References (Iited in the file of this patent 9 UNITED STATES PATENTS 2,750,100 Geisman June 12, 1956 2,880,923 Levkotf Apr. 7, 1959 2,970,739 Levkofi Feb. 7, 1961 FOREIGN PATENTS 474,120 Canada June 5, 1911 

